Hendrik Vansompel

Optimized Design Considering the Mass Influence of an Axial Flux Permanent-Magnet Synchronous Generator With Concentrated Pole Windings

In this paper, the efficiency optimization of an axial flux permanent-magnet synchronous generator with concentrated pole windings is examined for a 3.6 kW/2000 rpm combined heat and power application. Because the efficiency of the machine is important, specific measures are taken in order to reduce losses in the machine: thin laminated grain oriented material in the teeth, concentrated pole windings, and segmented magnets. A study of the influence of a limited set of geometry parameters on the efficiency of this type of machine is done, using both analytical and finite-element methods. In the analytical as well as in the finite-element model, the inherent 3-D geometry of the axial flux machine is approximated by multiple 2-D models at different radii in circumferential direction. Afterwards, the influence of mass on the optimal values of the geometry parameters and the efficiency is considered, and it is found that mass can be seriously decreased with only a small reduction in efficiency. Finally, the results of both methods are compared with measurements on a prototype to evaluate their validity.

Axial-Flux PM Machines With Variable Air Gap

Laminated soft magnetic steel is very often used to manufacture the stator cores of axial-flux PM machines. However, as the magnetic flux typically has main components parallel to the lamination plane, different magnetic flux density levels may occur over the radial direction: High flux densities near the saturation level are found at the inner radius, while the laminations at the outer radius are used inefficiently. To obtain a leveled magnetic flux density, this paper introduces a radially varying air gap: At the inner radius, the air gap is increased, while at the outer radius, the air gap remains unchanged. This results in equal flux densities in the different lamination layers. As the total flux in the stator cores is decreased due to the variable air gap, the permanent-magnet thickness should be increased to compensate for this. The effect of a variable air gap is tested for both a low-grade non-oriented and a high-grade grain-oriented material. For both materials, the redistribution of the magnetic flux due to the variable air gap results in a significant decrease of the iron losses. In the presented prototype machine, the iron losses are reduced up to 8% by introducing a variable air gap. Finally, a prototype machine is constructed using an efficient manufacturing procedure to construct the laminated magnetic stator cores with variable air gap.

A Multilayer 2-D–2-D Coupled Model for Eddy Current Calculation in the Rotor of an Axial-Flux PM Machine

On the rotors of an axial-flux PM machine, NdFeB permanent magnets (PM) are very often placed because of their high energy density. As the NdFeB-magnets are good electric conductive, electric currents are induced in the magnets when they are exposed to a varying magnetic field. This varying magnetic field has two causes: variation of the airgap reluctance due to the effect of stator slots and armature reaction due to the stator currents. As axial-flux PM machines have an inherent 3-D-geometry, full 3-D-finite-element modeling seems necessary to calculate the eddy currents in the PM and to evaluate their corresponding losses. In this paper, however, the 1-D airgap magnetic fields of multiple multilayer 2-D finite-element simulations are combined to a 2-D airgap magnetic field using static simulations. In a subsequent step, this 2-D airgap magnetic field is imposed to a 2-D finite-element model of the PM to calculate the eddy currents and eddy current losses. The main benefit of this multilayer 2-D-2-D coupled model compared to 3-D finite-element modeling is the reduction in calculation time. Accuracy of the suggested multilayer 2-D-2-D coupled model is verified by simulations using a 3-D finite-element model.

A Combined Wye-Delta Connection to Increase the Performance of Axial-Flux PM Machines With Concentrated Windings

In this paper, a combined wye-delta connection is introduced and compared with a conventional wye-connection of a concentrated winding. Because the combined wye-delta connection has a higher fundamental winding factor, the output torque is higher for the same current density when a sinusoidal current is imposed. As the combined wye-delta connection has only a minor influence on the losses in the machine, the efficiency of the machine is also increased. The combined wye-delta connection is illustrated in detail for an axial-flux permanent-magnet synchronous machine with a rated power of 4 kW at a fixed speed of 2500 r/min, using finite element computation and measurements on a prototype machine.

Evaluation of a Simple Lamination Stacking Method for the Teeth of an Axial Flux Permanent-Magnet Synchronous Machine With Concentrated Stator Windings

In this paper, a simple lamination stacking method for the teeth of an axial flux permanent-magnet synchronous machine with concentrated stator windings is proposed. In this simple lamination stacking method, only two lamination profiles are used and are stacked alternately. To evaluate the performance of this stacking method, a comparison is made between the proposed method with two profiles and a conventional stacking method that uses different profiles for each lamination layer, using a multilayer 2-D finite element model.

A computationally efficient method to determine iron and magnet losses in VSI-PWM fed axial flux permanent magnet synchronous machines

For electrical machines with a 3-D geometry, such as axial flux permanent magnet machines, the computation of iron and magnet losses in the case of pulsewidth modulation (PWM) supply could be performed by a transient 3-D finite element model (FEM) coupled with an electrical circuit. To reduce the CPU time, in this paper, these losses are computed with acceptable accuracy without using a 3-D transient FEM. The multislice technique is used with a 2-D static FEM, combined with a state space model of the machine. A Preisach hysteresis model is considered to evaluate the iron loss during minor loops. The loss in the electrical steel and in the magnets is evaluated for several PWM frequencies as well as for different segmentations of the magnets.

Comparison of Methods for Permanent Magnet Eddy-Current Loss Computations With and Without Reaction Field Considerations in Axial Flux PMSM

This paper presents an analytical solution of the eddy currents in the permanent magnets (PMs) in the axial flux PM synchronous machine using a coupled solution of Maxwells equations and electric circuit network. This is based on calculating the axial field in an accurate way on the surface of the PM. This method is able to consider the effect of armature field and slots. The eddy currents are obtained by imposing this solution on the PM which is modeled by a simple electric network. This network is composed of simple resistances and inductances. The inductances are used to model the reaction field effect of the eddy currents flowing through the PM and also the skin effect. To show this effect, the machine is excited with different sources at different speeds. In addition, a variant of the model is made that neglects the inductances, in order to show in which conditions this low-frequency approximation is acceptable. It is concluded from this paper that inclusion of the reaction field is necessary when the machine is excited by a pulsewidth modulated (PWM) current, while for a sinusoidal excitation, the reaction field effect has minor contributions to the total eddy losses. In addition, the reaction field has major influence at higher speeds rather than lower speeds for PWM injection. In conclusions, for a preliminary design, the resistance model without the reaction field computation would be enough for the calculation of the PM losses. The circuit model is also capable of obtaining the solution with PM segmentation. In this paper, different PM segments were studied from the circuit model and the finite-element (FE) model point of view. Compared with the FE model, the circuit model has the advantage of flexibility in geometrical machine parameters, less CPU time, and accurate results for the PM losses up to 10%.

Torque Analysis on a Double Rotor Electrical Variable Transmission With Hybrid Excitation

An electrical variable transmission (EVT) can be used as a power splitting device in hybrid electrical vehicles. The EVT analyzed in this paper is a rotating field electrical machine having two concentric rotors. On the outer rotor, permanent magnets (PMs) are combined with a dc-field winding, being the first implementation of its kind. The magnetic field in the machine as well as the electromagnetic torque on both rotors are a function of the q- and d-axis currents of the stator and inner rotor, as well as the dc-field current. To describe and fully understand this multiple-input multiple-output machine, this paper gives an overview of the influence of the different current inputs on the flux linkage and torque on both rotors. Focus is given to the hybrid excitation in the d-axis by combining the dc-field current and the alternating currents. This has the advantage compared to other EVT topologies that unwanted stator torque can be avoided without stator d-axis current flux weakening. Results of the analysis are presented by means of the torque to current characteristics of a double rotor PM-assisted EVT, as well as the torque to current ratios. The machine characteristics are finally experimentally verified on a prototype machine.

Comparison of Three Analytical Methods for the Precise Calculation of Cogging Torque and Torque Ripple in Axial Flux PM Machines

A comparison between different analytical and finite-element (FE) tools for the computation of cogging torque and torque ripple in axial flux permanent-magnet synchronous machines is made. 2D and 3D FE models are the most accurate for the computation of cogging torque and torque ripple. However, they are too time consuming to be used for optimization studies. Therefore, analytical tools are also used to obtain the cogging torque and torque ripple. In this paper, three types of analytical models are considered. They are all based on dividing the machine into many slices in the radial direction. One model computes the lateral force based on the magnetic field distribution in the air gap area. Another model is based on conformal mapping and uses complex Schwarz Christoffel (SC) transformations. The last model is based on the subdomain technique, which divides the studied geometry into a number of separate domains. The different types of models are compared for different slot openings and permanent-magnet widths. One of the main conclusions is that the subdomain model is best suited to compute the cogging torque and torque ripple with a much higher accuracy than the SC model.

Improving the rotor position estimation in permanent-magnet synchronous machines with a low-resolution position sensor

In this paper, a rotor position estimation based on a low-resolution position sensor is proposed. As vector control of an ac permanent-magnet synchronous machine requires the rotor position with sufficiently high resolution, the low-resolution sensor signal is transformed into a spatially quantized rotating vector and based on this vector, a vector-tracking observer calculates the corresponding high-resolution rotor position. The implementation of a basic vector-tracking observer topology is discussed. To reduce the remaining position estimation errors, two improvements are introduced: speed dependent observer gains and a reduction of the harmonic content in the input vector of the vector-tracking observer. These result in a sufficiently low position estimation error. The performance of the vectortracking observer is studied in steady state and in transient state by simulation as well as experiments on a hardware setup.